Compact Yarns Research Articles

Effects of finishing processes on physical properties of knitted fabrics produced by recycled cotton fibers

This study examines conventional wet-finishing processes applicable to fabrics containing recycled cotton fibers. The knitted fabrics were produced using open-end and compact yarns, with up to 80% of the cotton fibers being obtained from mechanical recycling of pre-consumer textile wastes. The study evaluated the effects of these finishing processes on the physical properties of the fabrics based on the recycled fiber ratio, yarn type, and yarn count. After determining the parameters for enzymatic bio-polishing, scouring, and color removal processes, two sequential finishing routes were designed: using the fabrics as mélange without a dyeing process (F1) or coloring them with color stripping and subsequent dyeing (F2). The resulting fabrics were tested for bursting strength, pilling resistance, weight, thickness, air permeability, and abrasion resistance, and the results were evaluated statistically. The study demonstrated that compact yarns provide superior strength, particularly when the F2 process was employed. The F2 process resulted in high pilling resistance and increased breathability of recycled knitted fabrics. The study concluded that the quality of fabrics containing recycled cotton fibers could be optimized by the selection of the appropriate finishing processes.

Twisting process of basalt fibers in water: The effects of water on microscopic structure and spinning property

Basalt fibers (BFs) are eco-friendly and natural high-performance fibers, specifically engineered for use in protective clothing, offering significant benefits. However, the inherent brittleness of this inorganic fabric not only poses challenges in processing but also renders it uncomfortable for wear. Consequently, there is an urgent need to modify BFs to enhance their torsional property and skin compatibility. Herein, we immersed BFs in water and twist them into yarn to investigate the effects of water erosion on BFs, specifically focusing on its impact on fiber structure and spinning performance. Under water's erosion, the BFs experienced ion-exchange reactions that compromised the silica framework, leading to a significant rise in both static and dynamic friction coefficients 162.5 % and 233.3 %, respectively, and a 1.53-fold improvement in torsional performance. The process of twisting in a water bath facilitated better fiber bundling, yielding a more compact yarn structure. This compaction reduced the occurrence of burrs following friction and enhanced both tensile and loop strength. At the fiber level, we utilized a simple water erosion method to enhance the twisting performance of basalt filament. This approach circumvents the disadvantages of large etching modification damage and poor sizing fastness, offering a novel method for the preparation of basalt twisted yarn.

Validation of fibre stress utilization model for modified ring spun yarns

To model the fibre stress utilization in modified ring spun yarns, we developed an analytical formula from the experimental data. The development of empirical formulae is carried out by using two different techniques, i.e., Cubic Spline and Artificial Neural Network methods. The experimental data of stress-strain curves of fibre and yarn has a large variation. To cope this variability, we used the smoothing spline technique to find the best-fit curve with respect to a reasonable smoothness. The best nonlinear smooth fitting can be used to extrapolate the experimental data beyond the breaking point. The modified ring spun yarns (compact, SIRO and SIRO-compact) with 20/1, 30/1 and 40/1 English count, produced from viscose staple fibre, were used to predict fibre stress utilization up to the yarn break by extrapolating the mean stress-strain curves of fibre and yarn by using the artificial neural network. Moreover, a new distribution function of fibre distribution in yarn has been proposed and successfully implemented for the prediction of fibre stress utilization in yarn. The new formulation helps to compute the fibre stress utilization in the yarn analytically. The validation of the proposed methodology is presented by comparing the numerical results with the experimental data. The predicted fibre stress utilization was in good agreement with the experimental fibre stress utilization for all types of modified ring spun yarns. It has been observed that SIRO-compact yarn exhibits improved fibre stress utilization as compared to SIRO and compact yarns. Moreover, the new distribution functions Gamma and Gaussian distribution were introduced in parallel with the Dirac delta function. In previous similar studies on ring, rotor and air-jet spun yarns, the proposed model can only predict the fibre stress utilization before the breakage point whereas the modified model, in this study, can predict the fibre stress utilization up to the breaking point.

Valorization of fabric wastes through production of recycled cotton yarns by compact ring and open-end rotor spinning

This study aims to determine the appropriate methods and parameters for the eco-friendly and sustainable production of finer yarns from recycled cotton fibers with acceptable quality and high recycled fiber ratios to transform pre-consumer textile wastes into better-quality products with value-added in the ready-made clothing industry. Cotton fibers were mechanically recycled from dyed fabric wastes. Mélange 100% cotton yarns were produced with different recycled/virgin fiber blend ratios (80/20, 72/28, 64/36, and 56/44) at different yarn counts (30 and 20 tex) and by different spinning methods (compact and open-end spinning) without any chemicals treatment. The yarn properties were tested and compared to determine the best production parameters. As a result of the study, it was seen that the yarn properties improved when the proportion of virgin cotton fiber in the yarn increased in parallel with previous studies. Besides, the yarn hairiness and unevenness of open-end yarns were better than compact yarns. On the other hand, using the compact spinning method led to higher yarn tenacity. The results indicated that the compact spinning method is advantageous in achieving the target of increasing the ratio of recycled fiber use with good tenacity for the production of %100 cotton yarns.

Moisture transport behaviour of Eli-Twist knitted fabric and its comparison with fabric made from yarns spun on different spinning systems

In this study, moisture management properties of knitted fabrics from Eli-Twist polyester and cotton yarns have been investigated. A comparative analysis with knitted fabrics from conventional ring-spun, siro-spun and compact yarns has also been made to assess its suitability. It is observed that polyester and cotton fabrics made from Eli-Twist yarn show very good permeability and moisture management characteristics.

Exploratory Study on the Properties of Compact Three-Roving Yarn: Comparison The Properties of Compact Spun, Compact Siro-Spun and Compact Three-Roving Yarns

This study presents the novel compact three-roving technology which developed on the working principle of siro-spun and compact spinning technologies. In the study, auxiliary parts of siro-spun and pneumatic compact spinning are newly designed for the production of compact three-roving yarns. The properties of new compact three-roving yarns were compared with compact spun and compact siro-spun yarns that produced at the same yarn count and at the same twist level from natural, synthetic and regenerated fibers. Besides, three-types of yarns were also used in the weft direction for the production of the woven fabric. Comparing yarn and fabric properties showed that, compact three-roving yarns have similar results to commercially used yarns in general. In addition, it should also be noted that three-roving yarn can be also used for specific purposes owing to its composite structure.

Study on the Frictional Behavior of Cotton Spun Yarn (Unraveled from Fabrics) after Different Wet Processing Stages

ABSTRACT Tearing strength of the woven fabric is an important mechanical property which directly decides the fabric serviceability. Yarn-yarn friction, one of the most important factors of fabric tearing strength, is a characteristic inherited from the surface and bulk properties of the interlacing yarns that decides the yarn interaction behavior. In this work, an experimental set-up was fabricated to measure the yarn-yarn friction on an UTM. By using this set-up, a study was carried out with the unraveled yarns obtained from commercial cotton woven fabrics consist of two sets of plain shirting fabrics, with different combinations of warp and weft type, i.e., ring-combed yarn, ring-compact yarn, and one set of plain suiting fabrics made of OE yarn. All these fabrics were processed through standard commercial chemical processing stages and samples were collected after each wet processing stages. It is found that, yarn-yarn co-efficient of friction (μ) of the compact yarn after finishing has the lowest μ, i.e., 0.32 as compared to ring and OE yarn μ of 0.36 and 0.45, respectively. However, after dyeing the μ is highest for all the yarns, i.e., μ of compact, ring and OE yarns are 0.35, 0.40, and 0.52, respectively.

The responsiveness rate of two types of compact cotton yarns structure to influence initial preparatory processes

The responsiveness rate of two types of compact cotton yarns structure to influence initial preparatory processes

Systematic study of the presence of microplastic fibers during polyester yarn production

Synthetic fibers, especially polyester, have over past decades managed to overtake and dominate the textile industry. Microplastic fibers are shed from synthetic textiles during their user phase, primarily during washing. However, there is little known about their origin, except that they are likely embedded in textiles already since their production. Therefore, we systematically examined the presence of microplastic fibers during the process of yarn production. We started with one bale and took samples from the bale opening step throughout carding, sliver handling and finally to spinning. We extracted microplastic fibers from all samples in order to quantify and characterize them. We also investigated the impact of process parameters, especially 4 different spinning methods (ring, compact, rotor, and air-jet spinning). We found microplastic fibers in all studied samples, ranging between 44 fibers/g to 8057 fibers/g. Rotor-spun yarns were identified as a material with a high content of microplastic fibers (2000–8000/g) while the other samples, including yarns spun with alternative methods, showed fiber numbers in tens and hundreds of fibers/g. Varying the operational settings of carding and spinning had none to minimal impacts on fiber number with the exception of rotor spinning, where we observed a 4 fold increase when the speed was increased by 25%. The released fibers have each a unique fiber length distribution with varying medians: 210 μ m for rotor yarns, 330 μ m for air-jet yarns and 530–580 μ m for ring and compact yarns. The results from this study will allow textile companies to select processes or operating conditions that minimize the presence of microplastic fibers. • Microplastic fibers are present in the yarn production from the initial step (bale). • The spinning method affects the quantity and the length of microplastic fibers. • Rotor-spun yarns show notably higher microplastic fiber releases than other yarns.

Enhancing the quality of elastane-cotton core yarn by compact spinning

The quest for highly stretchable fabrics with good aesthetic and functional properties has led researchers to constantly involve in mingling of natural and synthetic fibers. Elastane-cotton core yarns have an increasing demand due to their wear comfort and stretch-to-fit properties; therefore, efforts are still going on to optimize the yarn properties to meet the requirements for diversified applications. With a view to enhancing the appearance and performance characteristics of elastane-cotton core yarns, the present work was undertaken to manufacture them by exploiting the most modern and versatile pneumatic compacting mechanism, namely Suessen's EliTe compact spinning system. Elastane-cotton core yarns of different counts (20 tex, 30 tex and 60 tex) were produced with compact and conventional ring spinning system. The difference in morphology and physical properties of two types of yarns were compared after a thorough investigation by scanning electron microscope, evenness tester and strength tester. The results exhibited a noticeable decrease in hairiness, hairiness variation and neps values, especially seed-coat neps, for elastane-cotton compact core yarn. Unevenness & imperfection of compact core yarns were also found to be decreased that were reflected to the proportional enhancements in tenacity & elongation values. The overall observation reveals the potential of pneumatic compacting mechanism in obtaining elastane-cotton core yarn with superior structure and improved mechanical properties.

İnce Numara Kompakt İpliklerin Katlama-Bükümünde Hamel Büküm (Elasto-Twist) Teknolojisinin Kullanımı ve İplik Özellikleri

Tekstil sektörünün ana hammaddesi olan iplik, tek kat olarak üretildiğinde bazı fiziksel özellikleri sınırlı kalabilmektedir. Ayrıca değişen ve gelişen nihai ürün özellikleri paralelinde tek kat ipliklerden ekstra fiziksel özellikler istenmektedir. Bunun bir sonucu olarak katlama ve büküm prosesleri, iplikteki fiziksel özellikleri geliştirmek amacı ile başvurulan bir yöntem haline gelmiştir. Günümüzde en fazla kullanılan büküm yöntemi two-for-one büküm yöntemidir. Her ne kadar çok az bilinse de Hamel büküm (elasto-twist) yöntemi de uygulanmakta olan bir diğer yöntemdir. Bu çalışmada Hamel büküm sisteminde beş farklı büküm değerinde Ne 70/2 iplik üretilmiştir. Üretilen iplik numunelerinin Uster, CV, kalın yer, ince yer, neps, mukavemet ve tüylülük değerleri tespit edilmiş ve elde edilen veriler değerlendirilmiştir. Elde edilen bulgular, büküm etkisi altında incelenen kalite parametrelerinde tüm numune grupları üzerinde iyileşme olduğunu ve bu sistemde de büküm seviyesinin kalite parametreleri üzerinde anlamlı bir etkisinin olduğunu göstermiştir.

Simulation of airflow in the condensing zone of a modified compact spinning device and analysis of its yarn properties

Compact spinning is a new type of ring spinning. Its main purpose is to reduce the yarn hairiness and widely put into practice in stable fiber spinning. In this article, a new compact spinning device for long fiber is put up: lateral compact spinning with pneumatic groove. The simulation and characterization of the flow field in the condensing zone are made by computational fluid dynamics software. Then the distribution rules of static pressure and velocity in the condensing zone are carried out at the different position of the lateral groove. In the numerical simulation, the results show that the condensing airflow is largest at the center of the lateral groove and the gathering velocity is largest at the edge of the lateral groove. Meanwhile, the four different yarns are spun and the yarn properties are compared. By testing the hairiness, strength and twist properties, analyzing and comparing the results with the data of four spinning yarns, we find the best fibrous strand feed in position. The theory analysis gives foundation and explanation for the experiment, and also provides a theoretical basis for optimizing the properties of long fiber compact spinning yarns in production practice.

Strong and multi-responsive composite coiled yarn based on electrospun polyamide-6 nanofiber and carbon nanotube

Polymer based coiled yarns are a new kind of smart materials hold promising applications in various high-tech fields such as artificial muscle, soft robotic, prosthesis, and smart textile. In this paper, we report a facile method for preparation of composite coiled yarn consisted of polyamide-6 (PA6) and single-walled carbon nanotube (SWNT). The homogeneous dispersion of SWNT is first prepared and sprayed on both sides of PA6 nanofiber non-woven, the composite non-woven is then twisted into compact coiled yarn. The uniform coating of PA6 non-woven by SWNT is demonstrated and the incorporation of continuous SWNT network has significantly improved the mechanical properties of composite yarn in comparison with pure PA6 yarn. The good photothermal and electrothermal properties of the SWNT network also endow the composite yarn with near infrared light and electricity responsive ability in terms of contraction that are not possessed in pure PA6 coiled yarn. In addition, the controlled contractive behavior of composite yarn by different voltage is also demonstrated. It is expected that this work could provide an alternative method for strong and multi-responsive composite coiled yarns.

Compact Spinning in Cotton-based Core-spun Yarn: A Review

In today's world, textile outfits are chosen not only for their functional properties but also for their comfort. As cotton is synonymous with comfort in textile industries, cotton-based core-spun yarn is becoming increasingly popular day by day, where the core element satisfies the functional properties and the cotton sheath provides a good hand feel and comfort. At the beginning of the twenty-first century, researchers developed a new spinning modification known as the compact spinning system to improve yarn quality. In cotton-based compact core-spun yarn, reduced hairiness, unevenness (U%), thick place, thin place, neps, and increased strength are achieved. This will also lead to significant abrasion and piling resistance, higher air permeability, lower thermal resistance, and higher Relative Water Vapor Permeability (RWVP). This review paper illustrates the advantages of spinning cotton-based core-spun yarn in the compact spinning system.

Production of Fine Count Yarns from Some Extra-long Egyptian Cottons on Different Spinning Systems

The current research was carried out to produce fine count yarns from extra-long Egyptian cotton varieties using compact and ring spinning systems.in addition, to compare between compact yarns and ring yarns in terms of their physical and mechanical properties. Three commercial extra-long staple Egyptian cottons Giza92, Giza93 and Giza 96 were used to produce four linear densities of 80, 100, 120 and 140 at 3.6 twist multiplier. Results obtained showed that Giza 92 was surpassed significantly other extra -long staple varieties. It recorded the highest mean values of yarn strength and yarn evenness While, the same variety recorded the lowest mean values of yarn hairiness and imperfections. Compact yarns were much better than yarns spun on the ring spinning in yarn strength, yarn elongation, evenness, yarn imperfections and yarn hairiness. Yarn count 80,s gave higher single yarn strength (20.89cN/tex), yarn elongation (5.03%) and yarn evenness (17.49%) and lower yarn hairiness (2.04) and imperfections than yarn count 140s. Single yarn strength, yarn elongation and yarn evenness were decreased with increasing yarn count. While the number of neps, hairiness, the number of thin and thick places were increased with increasing yarn count. Concerning, the effect of interaction between cotton varieties × yarn counts × spinning systems on yarn quality properties. Yarn count 80s recorded the highest mean values of yarn strength (23.14, 21.1 and 20.2 cN/tex) and yarn evenness (17.72, 16.53 and 16.79%) for varieties Giza92, Giza93 and Giza96, respectively for compact spinning system. Yarn strength at count 80, 100, 120 and 140 correlated negatively and highly significant with micronaire value and maturity ratio.

Effect of blending ratio on the hollow coffee carbon polyester/cotton blended yarn

The effect of blending ratio on the performance of hollow coffee carbon polyester/cotton blended compact siro-spun yarn was investigated. Five blend ratios of hollow coffee carbon polyester/cotton fiber (i.e. 20/80, 35/65, 50/50, 65/35, and 80/20) and polyester/cotton fiber 35/65 were designed, and six groups of 14.6 tex yarn were spun by compact siro. Indices for the performance of the yarn (surface morphology, evenness, hairiness, tensile property, and hydroscopicity) were tested and analyzed. The regression analysis showed the excellent linear relationship between the content of hollow coffee carbon polyester and each performance index was obtained. Cubic curve models were built to comprehensively evaluate the performance of the yarn. The blending effect in these yarns was evaluated using the Hamilton transfer index. The tests results show that with the increase of the content of hollow coffee carbon polyester in the blended yarn, the evenness and tensile properties of the hollow coffee carbon polyester/cotton blended yarn continue to increase, whereas the hairiness index and moisture regain of the yarn gradually decrease. With the change of blending ratio, the transfer index of each fiber in hollow coffee carbon polyester/cotton blended yarn will change. When the content of hollow coffee carbon polyester is more than or equal to 50%, it has the tendency to preferentially distribute inward, whereas the cotton fiber has the tendency to preferentially distribute outward. When the content of hollow coffee carbon polyester is less than 50%, the reverse is true. The comprehensive evaluation value of the yarn performance decreased first and then increased with the increase in the content of hollow coffee carbon polyester.

Numerical and experimental approach towards an energy-efficient compact spinning system

Compact spinning with a lattice apron has recently become a very attractive approach for pneumatic compact yarn production spinning systems. One of the main challenges with use of this method is the high negative pressure that leads to high energy consumption. In response to this challenge, we present a numerical and experimental investigation of the effects of a three-dimensional (3D) printed guiding device on the airflow characteristics and yarn properties. Initially, the 3D numerical model of the compact spinning system was set up based on the real geometrical dimensions. Secondly, the 3D prototype was developed, simulated, and analyzed using Solidworks and Ansys. Ultimately, the design, which exhibited low negative pressure along the model domain, was adopted and then 3D printed to enable further experimental investigation. Airflow analysis results illustrated that when using the guiding device with low negative pressure, the active area of negative pressure was increased. This was due to the existence and the special design of the guiding device that prevented the decrease of the negative pressure with atmospheric pressure. This increased the transverse condensing force, which was beneficial for twisting the free-end fiber around the fiber bundle. Experimental results revealed that the three yarns spun with the guiding device achieved significant energy saving when the guiding device was used. Moreover, these yarns spun with the guiding device had better strength, hairiness, and evenness than those spun without a guiding device. The model developed can be further improved and utilized for commercial purposes, as it significantly reduces energy costs while improving yarn properties.

Prediction of Cotton Yarn’s Characteristics by Image Processing and ANN

Machine learning and computer vision were employed in quality assessment in the textile field for more objectivity and less expense. The estimation of yarn various parameters is of great importance for the producers and customers in order to achieve optimal quality. This research utilized image processing and artificial neural networks in order to evaluate yarn tenacity, elongation%, coefficient of mass variation%, and yarn imperfections for ring-spun and compact cotton yarns. Cotton yarn samples were collected from two mills: ring spinning and compact spinning mills. The images were taken and image analysis was employed then feature vectors were defined as the inputs of the backpropagation neural networks. Two systems were built; each one contained three modules for the estimation of the different yarn’s properties. Using the multilayer network structure proved to improve the performance of the networks leading to better parameters’ modeling. Yarn properties estimation for different yarn types was achieved using a moderately priced method.

Investigation into four-roller compact spinning with air damper for improving yarn performance

Compact spinning, as a new kind of spinning technology, has gained wide attention because of its great reduction in spinning triangle and yarn hairiness. In order to meet the demand of high-grade clothing, research on further improving the performance of compact spun yarn is the emphasis. Of all the existing compact spinning systems, the four-roller compact spinning with lattice apron is most widely used at present because of its low cost. Therefore, this paper aims to put forward a new kind of device to improve yarn performance for four-roller compact spinning systems. Related experiments have been done to verify the efficiency of the device, and the mechanism is analyzed by computational fluid dynamics. The numerical simulation shows that the device can change the direction of airflow and increase the velocity in the directions of transverse condensing and thickness. It is shown that the air damper is convenient to use and has potential applications in spinning compact yarns with better performance.

Development of hemp-blended cotton fabrics and analysis on handle behavior, low-stress mechanical and aesthetic properties

Cotton is the most popular natural fiber used in apparel industry world over. Although cotton is cultivated in approximately 2.4% of the world’s arable land, it accounts for 24% of the world’s insecticide market. Industrial hemp is considered as the most sustainable raw material as substitute of cotton in textile industry. However, there are several challenges associated with hemp processing as the fiber is coarse, stiff and it has comparatively poor spinnability particularly when 100% hemp is processed in ring spinning system. The purpose of this paper is to investigate the aesthetic and low-stress mechanical properties, and handle value of the plain woven hemp-blended cotton fabrics. The 16Ne and 30Ne linear density compact and ring yarns were produced and were used to manufacture plain woven suiting and shirting fabrics, respectively. Crease recovery angle, pilling, tear and tensile strength, and handle value of the fabrics were determined.